®

®
T/PUMP
TP500 / TP500C
Heat Therapy System

LISTED 304L

STANDARD (NORME)
C22.2 NO. 125 RISK
CLASS (CATEGORIE
DE RISQUES) NO. 2G

SERVICE MANUAL
P/N 11950-000 9/03
CONTENTS
CONTENTS
SafetyPrecautions ..................... 1
Introduction ......................... 2
Features ............................ 3
Specifications ........................ 4
OperatingInstructions .................. 5
Storage/Cleaning ...................... 7
Theory of Operation ................... 8
FunctionalCheckandSafetyInspeciton ....... 10
InspectionForm ...................... 15
Disassembly/Reassembly ................. 16
Calibration .......................... 19
Troubleshooting ...................... 21
ReplacementParts ..................... 27
Warranties .......................... 30
ILLUSTRATIONS
1 T/Pump® Heat Therapy System ........ 2
2 Features/Specifications .............. 3
3 Clik-Tite® Connectors .............. 5
4 Colder-styleConnectors ............ 5
5 T/Pump Components .............. 9
6 Motor ........................ 11
7 TPC1 Test Covers ................ 22
8 Functional Check Test Diagram ....... 23
9 Circuit Diagram for T/Pump .......... 24
10 Circuit Diagram for TPC1 Test Cover ... 25
11 Exploded View of T/Pump ........... 26
T/PUMP, T/PAD, Mul•T•Pad, Clik-Tite, and Gaymar are registered trademarks of Gaymar Industries, Inc. U. S. PATENT 4,068,870
©2001.GaymarIndustries,Inc.Allrightsreserved. www.gaymar.com
SERVICE MANUAL
TP500/TP500C T/PUMP
BEFORE YOU BEGIN . . .
Read and understand this
T/PUMP SERVICE MANUAL and all
PRECAUTIONS (see page 1) prior to
servicing the T/Pump.
Thepurposeofthismanualistoprovideoperation,
service, and repair information for GAYMAR heat
therapypumps.
RECEIVING INSPECTION
Checktheshippingcartonfordamageimmediately
uponreceipt.Ifpackagedamageisdiscovered,the
deviceshouldbeunpackedwiththecarrier'sagent
present. Any claims for shortage or damage must be
filedwiththedeliveringcarrierbythepurchaser.Do
not return pumps damaged in shipment to GAYMAR
withoutcontactingourTechnicalService
Department for advice (see phone numbers below).
If damaged goods are returned to GAYMAR without
notifyingthecarrier,GAYMARwillassumethe
repairswillbemadeatthecustomer'sexpense.
TO RETURN PUMPS TO FACTORY
FOR REPAIR OR EXCHANGE
Merchandise returned to GAYMAR must be
accompanied by a Return Goods Number (RG#),
issued by GAYMAR, authorizing goods to be
returned.CallCustomerServiceorTechnical
Serviceat
(716)662-2551
1 800 828-7341
Advisemodel,serialnumber,andnatureofproblem.
You will be given a Return Goods Number (RG#).
The serial number is on the back of the T/Pump
(seefigure2,p.3).
SERVICE MANUAL SAFETY PRECAUTIONS
TP500/TP500C T/PUMP

DANGER

• Risk of explosion. Do not use in the presence of flammable

anesthetics.
• Risk of electric shock.Disconnect power before servicing
the T/Pump.

WARNING

• This device pumps warmed water through a pad. Set pad

temperatureonlyasprescribedbyandundertheguidanceofa
physician.Monitorthepatient'stemperatureandskincondition
every20minutesorasdirectedbyaphysician.Failureto
adhere to these warnings could result in patient injury.
ThefollowingGroups/Conditionsrequireadditionalsurveillance:

Group/Condition at risk Potential injury

Pediatric patients Hyperthermia/
hypothermia
Patients with impaired circulation Ischemia
Areas of application are under pressure Ischemia
In combination with topical solutions whose toxicity Chemical
may be affected by the application of heat injury
In combination with other heat sources Thermal injury

• Onlyqualifiedmedicalservicepersonnelshouldrepairthe
T/Pump. Improper repair may result in death or
serious injury, equipment damage, or malfunction.
• Always perform the FUNCTIONAL CHECK AND SAFETY
INSPECTION(pp.10-14)aftermakingrepairsandbefore
returning the T/Pump to patient use. Document your
findings on the INSPECTION FORM (p. 15). Improper
repair may result in death or serious injury,
equipment damage, or malfunction.

CAUTION

• Do not perform any powered tests with the reservoir empty.

Damage to the T/Pump may result.

1
 SERVICE MANUAL
INTRODUCTION TP500/TP500C T/PUMP

SinglePad MultiplePads

Figure 1—T/Pump Heat Therapy System

Heattherapyiseffectiveinthedilationofbloodvessels,therebyincreasing
thebloodflowtotheheatedarea.Heattherapyhasavarietyofuses,the
most common being treatment of aches and pains in joints and muscles.

The GAYMAR T/Pump® Heat Therapy System provides a means of

applyingheattherapybysupplyingtemperature-controlledwaterthrougha
connector hose to a Gaymar T/Pad®. The hose is terminated in easy-to-use
Clik-Tite® orColder-styleconnectors.

TheT/Padprovidestheinterfacefordeliveringtheheattherapy.The
uniquebuttondesignallowswatertoflowandprovidestrouble-free
operation when the pad is folded. This reduces the number of pads your
facilitymustkeepininventory.Thepadsareappliedtothepartofthe
bodyrequiringheattherapy,andthecirculatingwatermaintainsthepadat
thesetpointtemperature.Thetemperaturesetpointiskey-operatedto
preventtampering.

The T/Pads can be interconnected (on model TP500 only) to provide

therapy to more than one body site at a time.

2
SERVICE MANUAL
TP500/TP500C T/PUMP
FEATURES

Figure2—T/PumpFeatures

FEATURES Attached Hose 10 ft (305 cm) dual hose. Connectors allow pads to be
connectedtothepump(seefigs.3and4,p.5).

Tip-over Turnsheateroffifpumpistipped.
Switch NOTE: This does not activate the OVER TEMP light.

HospitalID A label is provided on the back of the T/Pump for your

Label convenience.Useafelttiporballpointpentoaddany
requiredhospitalidentification.

OVER TEMP Indicatesthepumpandheaterhavebeenturnedoff.

Light ThislightisactivatedbythetwoOVERTEMPsafety
thermostats. Refer to the TROUBLESHOOTING section.

CircuitBreaker Whenthecircuitbreakertrips,thesmallbuttonin
thecenterwillextend1/4",exposingawhiteband.
Refer to the TROUBLESHOOTING section.

OVER TEMP Eitheroftwolimitthermostatswillshutoffpumpandheater

Safety if the high temperature limit is exceeded. TheOVER TEMP
Thermostats lightwillglow.RefertotheTROUBLESHOOTINGsection.

3
 SERVICE MANUAL
SPECIFICATIONS TP500/TP500C T/PUMP

SPECIFICATIONS Size(approx.) 8-1/8"x5-5/8"x6-1/4"

(20.6 cm x 14.3 cm x 15.9 cm)

Weight (empty) 5lbs,2oz(2.3kg)

Reservoircapacity 51 oz (1500 ml) maximum

Flowrate 9 gph (34 lph) minimum with pad attached

Ambientoperating 60°F to 90°F (15.6°C to 32.2°C)

temperatures

Storagetemperatures -30°Fto160°F(-34.4°Cto71.1°C)
(empty)

Temperaturesetpoint 85°F to 107°F (29.4°C to 41.7°C)

range

Averageoperating ±2°Fat107°Fsetting
temperatureaccuracy

Power cord 18 AWG, 3 conductor, 9 ft (274 cm), Type SJT

with molded,hospitalgradeplug

Circuitbreaker 3 amperes

1stbackuplimit Bimetallic(trippointfixed)
thermostat 110°F to 117°F (43.3°C to 47.2°C)
(manifoldmounted)

2ndbackuplimit Bimetallic(trippointfixed)
thermostat 110°F to 122°F (43.3°C to 50°C)
(wellmounted)

Currentleakage 100 microamperes maximum

Groundresistance 0.5 ohm maximum

Electricalrequirements
Voltage (VAC) 120
Frequency(Hz) 60
Current(amps) 1.8
Powerreq'd(watts) 200

Safetyapprovals Tested to UL 544 and CSA C22.2, No. 125

4
SERVICE MANUAL
TP500/TP500C T/PUMP OPERATING INSTRUCTIONS

T/Pumps are supplied with one of two types of hose connectors:

TP500 T/Pumps have Clik-Tite® connectors;
TP500C T/Pumps have Colder-style connectors.

CLIK-TITE® CONNECTORS
(on TP500):
ToattachClik-Titeconnectorsfromhosetopad:

1. Insertmalefittingsintofemalefittingswith
atwistingmotion(figs.3Aand3B).

2. Whenfittingsarefullyinserted,snaplocking
ringintoplace(figs.3Cand3D).

3. Todisconnect,simplyreversetheprocedure.

4. To open or close the hose pinch clamps:

• Open the clamp by pushing the serrated
end(fig.3E). Figure3A–3D—Clik-Tite® Connectors

• Close the clamp by pressing the clamp

together(fig.3F).

NOTE: Refer to figure 1 (p. 2) and

item 9 (p. 6) when connecting 3E 3F
multiple pads.
Figure 3E–3F—Hose Pinch Clamps

COLDER-STYLE CONNECTORS
(on TP500C):
1. ToattachColder-styleconnectorstoapad,
push the male coupling onto the female cou-
pling.Whenyouhearanaudible“click”,the
4A
connectorsarejoined(fig.4A).
2. TodisconnectColder-styleconnectors,press
down on the thumb tab of the female coupling.
Thecouplingswillpartiallydisconnect.Pullthe
malecouplingoutfullytodisconnect(fig.4B).

4B
Figure 4—Colder-style Connectors

5
OPERATING INSTRUCTIONS SERVICE MANUAL
TP500/TP500C T/PUMP

START-UP PROCEDURE 1. Beforefilling,alwaysattachaT/PadtotheT/Pumpconnectorhose(see

figs.3and4,p.5).Unkinkpadandhose.Openhoseclamps.

2. Open the fill cap on top of the pump. Fill the pump with room
temperature(i.e.,nothot)distilledwatertotheoperatinglevel
indicatedonthesideofthepump.
NOTE: Using tap water will decrease the life of the pump.

3. Inserttemperaturesettingkey.Settemperatureasprescribedbythe
physician.Removekeytopreventtampering.

4. Plugthepumpintoaproperlygroundedoutlet.

5. Turn on the power switch. The selected water temperature will be

reachedinapproximately20minutes.

6. Ifthewaterleveldropsbelowtheoperatinglevel,addwater.Donot
overfill. Overfilling can result in reduced pump motor life.

7. ApplyT/Padtothepatient.FollowT/Padinstructions.

8. Forspecifiedperformance,keepthepumpatorabovethelevelofthe
pad.

9. Ifthepumpisplacedbelowthepad(s),waterwilldrainintothepump
whenitisshutoff.Ifthepumphasbeenoverfilledorifmultiplepads
areconnected,excesswatercanleakoutontothefloororcause
reducedmotorlife.

SHUTDOWN PROCEDURE 1. Turnoffpumpbeforedisconnectingpad.Closeallhoseclamps.

Topreventwaterspillage,alwaysdisconnectpadfrompumpwith
connectorsraisedabovethelevelofthepadandpump.

2. ConnecttheT/PadClik-Titeconnectorstogether,whereapplicable.

3. Connect the ends of the T/Pump connector hose together

(TP500only).

6
SERVICE MANUAL STORAGE / CLEANING
TP500/TP500C T/PUMP

Storage (Short term) Disconnect pad. Connect ends of the connector hoses together,
whereapplicable.Openhoseclamps.Leavewaterinthereservoir.
Topreventhosekinks,coilthehoseratherthanfoldingit.Fastenthehose
andcordwithstrap.

Storage (Long term) Connect pad. Open hose clamps. Add 1/4 ounce GAYMAR MTA33
germicidalorequivalenttowateralreadyinreservoir.Runfortwo(2)
minutes. Drain pump. Close hose clamps. Disconnect pad. To prevent hose
kinks,coilthehoseratherthanfoldingit.Fastenthehoseandcordwith
strapandstorepump.

Draining Unplug the power cord. Disconnect the pad or hoses from one another,
keepinghosesatorabovetheleveloftheT/Pump.Removethefillcapand
inverttheT/Pumpoverasink.Whenallfluidhasdrainedfromthehoses
andreservoir,replacethefillcapandconnectthehosestogether,where
applicable.

Cleaning Unplug the power cord.

Tocleantheexternalsurfaces,useanon-abrasivecleaningsolution(such
as warm, soapy water) and a damp cloth.
Tocleanthefluidsystem,drainthepump.Fillthereservoirtotheoperat-
ing level indicated on the side of the pump. Add 1/4 ounce GAYMAR
catalogMTA33germicidalorequivalent.Setthetemperatureindicatorto
itslowestsetting(fullycounterclockwise).StarttheT/Pumpandcirculate
thesolutionforonehour.Drainthesolutionandrefillthepumpwith
distilledwater.Usingdistilledwaterretardsalgaegrowthandmineral
buildup.
Change the distilled water monthly or more often depending upon use.

Pads/Accessories For best results use only GAYMAR T/Pads® or Mul•T•Pads®. The unique
buttondesignallowswatertoflowandprovidestroublefreeoperation
whenthepadisfolded.Thisreducesthenumberofdifferentsizesofpads
yourfacilitymustkeepininventory.TheT/Padscanbeinterconnected(on
model TP500 only) to provide therapy to more than one body site at a
time(seefig.1,p.2).Forabrochurelistingthevariouspads,contactthe
GAYMAR Customer Service Department (see inside cover for telephone
numbers).
An optional bed bracket (model TP20A) is available to mount the T/Pump
on the footboard of a bed.

7
THEORY OF OPERATION SERVICE MANUAL
TP500/TP500C T/PUMP

WATER TEMPERATURE Therearefourdevicesthatcontroltheoperationoftheheaterinthe

CONTROL GAYMAR T/Pump:

• Thetemperaturecontrolleristhermistoractuated (fig.5,item1,p.9).
Thiscontrollerisadjustableoveratemperaturerangeof85°Fto107°F
(29.4°Cto41.7°C).Thedesiredwatertemperatureissetwithaspecial
removablekey(fig.5,item7).Topreventunauthorizedtemperature
settingchanges,removethekeyafterthetemperaturehasbeenset.

• Themanifoldbackuplimitthermostat(fig.5,item9)ismountedonthe
brassmanifoldblock(fig.5,item8).Thisthermostatsenseswater
temperature flowing to the pad and will shut off the pump and heater
andactivatethe OVERTEMP lightifthewatertemperatureexceeds
specificlimits.Thepurposeofthemanifoldbackuplimitthermostatisto
prevent the pump from providing water at too high a temperature to
thepad.

• Thewellbackuplimitthermostat(fig.5,item5)ismountedonthebrass
plate(fig.5,item11)thatextendsalongandundertheheater(fig.5,
item4)nearthebottomofthereservoir.Thisthermostatsenseswater
temperatureinthereservoirandwillshutoffthepumpandheaterand
activatetheOVERTEMPlightifthereservoirtemperatureexceeds
specificlimits.Thepurposeofthewellbackuplimitthermostatisto
both prevent the pump from providing water at too high a temperature
to the pad and to protect the pump from high temperature damage due
toalowwaterlevel.

• Thetip-overswitch(fig.5,item2;seealsofig.12,item64,p.27)is
mounted on the PC board. This mercury-type switch will shut off the
heaterifthepumpistippedmorethan45°fromtheverticalposition.

NOTE: The tip-over switch does not shut off the pump
motor or activate the OVER TEMP light.

FLUID SYSTEM Thepump(fig.5,item12)isasumpconfigurationdrivenbyanimpedance

protected,shadedpoleACmotor(fig.5,item6).

Thereturnhosefitting(fig.5,item10)ismachinedinternallytoactasan
orifice.Thismaintainsabackpressureinthepadtomakeitresistantto
flowrestrictions.

8
SERVICE MANUAL T/PUMP COMPONENTS
TP500/TP500C T/PUMP

FIGURE 5—T/PUMP COMPONENTS

TOP
(wireharnessremovedforclarity)

BOTTOM

9
FUNCTIONAL CHECK SERVICE MANUAL
TP500/TP500C T/PUMP

FUNCTIONAL CHECK & Thissectionisdesignedtoprovideacompletecheckofallpumpparam-

SAFETY INSPECTION eters.Theorderoftestsshouldbefollowedsothatthefunctionaltesting
canbecompletedintheleastpossibletime.
Follow the FUNCTIONAL CHECK AND SAFETY INSPECTION carefully, paying
particularattentiontotestsetups.Anydeviationfromthesetups,
procedures,ortestequipmentmayresultinincorrectormisleadingresults.
Beforemakinganyrepairs,besuretorecheckyourtestsetup,procedure,
andtestequipment.

DANGER

Risk of electric shock. Disconnect power before servicing the

T/Pump.

WARNING

• Onlyqualifiedmedicalservicepersonnelshouldrepairthe
T/Pump. Improper repair may result in death or serious
injury, equipment damage, or malfunction.
• Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION
aftermakingrepairsandbeforereturningtheT/Pumptopatientuse.
Document your findings on theINSPECTION FORM (p. 15).
Improper repair may result in death or serious injury,
equipment damage, or malfunction.

CAUTION

Do not perform any powered tests with the reservoir empty.

Damage to the T/Pump may result.

INTERVAL Toassuretheoptimumperformance,dependabilityandsafety,thefollowing
shouldbeperformedonceperyear(orasspecifiedinthefacility's
preventivemaintenanceprogram)andaftermakingrepairs.

REQUIRED TOOLS TPT9 ---------- GAYMAR Flow and Temperature Tester

[When testing TP500C, use also an
Adaptor Hose Assembly, P/N 77926-000)
TFC1 ---------- Thermometer, 30°F to 125°F (-2°C to 52°C), 1°C
accuracy,12"long,3"immersion(e.g.,Brooklyn
Thermometer #73544 or equivalent, Brooklyn
Thermometer Co., Farmingdale, NY 11735)
T/Pad --------- Any GAYMAR “12” or “22” series T/Pad;
or, TP612 or TP622 pad as applicable
TPC1 --------- GAYMAR T/Pump Test Cover
GroundResistanceTester
Current Leakage Meter
DistilledWater --- 2liters(approximate)
SyntheticOil ----- Anderol #465 (GAYMAR P/N 77137-000)
INSPECTION FORM - (p.15)

10
SERVICE MANUAL FUNCTIONAL CHECK
TP500/TP500C T/PUMP

PHYSICAL CONDITION 1. Examinethelinecordalongitsentirelengthforphysicaldamage,such

CHECK ascutsorcrackedinsulation.Adamagedlinecordshouldbereplaced
ratherthanrepaired.Checkthequalityofthestrainreliefsatbothends
ofthelinecord.
2. Examinetheplugonthelinecordtobesureitisingoodcondition.If
unit has non-molded type plug, open plug and check for wire breakage
andlooseterminalscrew(s).Ifdefective,replacewithahospitalgrade
plug.Torqueterminalscrew(s)andoutsidehousingscrewsto12in.-lbs.
3. Operateswitchesandcontrolsettingsatallpositions.Ifdefective,
replace.
4. Visuallyinspectpump.Checkforcrackedordamagedplasticparts.
Be sure unit is unplugged. Remove retainer cap. Remove four (4)
screwsholdingcoverandremovecover.(Besurenottolosefillneck
gasket.)Performvisualinspectionofallinternalparts.Removeany
accumulated dirt with a vacuum cleaner or compressed air hose. Leave
coveroffforbalanceofinspection.
5. Checkconnectorsforcracks,missingOrings,orotherdamage.
Replaceconnectorsifnecessary.

MOTOR LUBRICATION 1. Locatethemotormanufacturer'sIDonthetopbearinghousing.

IfthepumpmotorisbyJakel,nooilingisrequired.Ifthepumpmotor
isbyUppco,proceedwiththefollowingoilinginstructions.

2. Oil the pump motor every 6 months with Anderol #465 (GAYMAR
P/N 77137-000) or equivalent to extend the life of the T/Pump motor.
Anderol#465isasyntheticoil.Donotuseapetroleum-basedoilsince
itwillleavearesidueasitbreaksdown,causingthemotortoseize.
Addfour(4)dropsofoiltotheventholeinthebearinghousingofthe
motorlocatedbelowthefan.Usingamicrooiler,applyasimilar
amounttothelowerbearingatthelocationindicatedinfigure6.

NOTE: Early versions of

the pump motor have an
oiler tube which does
noteffectivelydistribute
oil to the lower bearing.
Do not use the oiler
tube to apply oil to the
lower bearing. Use a
micro oiler to apply oil
directly to the locations
shown in figure 6.

Figure 6—PUMP MOTOR

11
 SERVICE MANUAL
FUNCTIONAL CHECK TP500/TP500C T/PUMP

TPC1 TEST COVER 1. When connecting the test cover, do not remove any wiring connec-
INSTALLATION tionsintheT/Pump.Simplyclipthetestcoveralligatorclipsonto
terminalswiththesamecolorwire.
2. ConnectTPC1testcover(seefig.7A/7B,p.22and10A/10B,p.25).
Always match the color of TPC1 wiring connections to the color of
T/Pumpwiring.Besuretokeepwiresawayfromfan.Installtestcover.
Besuretopushcoverontightly.Itisnotnecessarytoinstallscrews.
3. Connect pump with test cover, pad, TPT9 flow/temp tester, and
adaptorhoseassemblyifrequired(seefig.8,p.23).BesuretheTPT9is
connectedtothesupplysideoftheT/Pump,beforethepad.
4. Fillunitwithroomtemperaturedistilledwaterandreplacefillcap.
Connectpad.Placepadonaninsulatingmaterial(e.g.,clothortowel).
5. SetbothtestcoverswitchestotheOPENposition.

GROUND RESISTANCE DANGER

CHECK
Risk of electric shock. Be sure unit is unplugged when performing
thegroundresistancetest.

1. Use a ground resistance meter to measure the resistance between the

groundpinontheplugandthebrassmanifoldblock(fig.11,item47).
Contactisavailablethroughtheholewherethehosesconnecttothe
pump. This value should not be more than 0.5 ohm.

CURRENT LEAKAGE Itwillbeconvenienttocheckcurrentleakageatthispointsincetheunitis

CHECK fullandconnectedtoapad.

1. Measurethemaximumcurrentleakageinallcombinationsofheater
“ON” or “OFF” and power switch “ON” or “OFF.” Access to chassis
groundforcurrentleakagetestingisavailablethroughtheholewhere
thehoseconnectstothepump.Thehighestreadingistypicallyless
than 30 microamperes. The maximum allowable reading is 100
microamperes.Recordthehighestreading.
2. Disconnectleakagemetersetup.

TIP-OVER SWITCH CHECK 1. Checkthetip-overswitchatthispoint,sincethetestcoverison

andtheunitisfull.Settemperaturetomaximum(107°F)ondial.
Theheaterindicator(fig.7,p.22)willbeon.Tiptheunitapproxi-
mately45°.Iftheheaterindicatorgoesout,thetip-overswitchis
operating. Ifnot,repairorreplacethePCboard(p.17).Record
results.

12
SERVICE MANUAL
TP500/TP500C T/PUMP FUNCTIONAL CHECK

FLOW RATE TEST 1. Be sure the pad is flat and warm (approximately 107°F) and at the same
levelasthepump.TopofTPT9float(seefig.8,p.23)shouldreadat
least9gph.Recordreading.
NOTE: If flow is below 9 gph, refer to TROUBLESHOOTING section
(p.21).

OPERATING 1. Make sure temperature is set to maximum (107°F) on dial. Allow unit
TEMPERATURE TEST tocometoasteadytemperature,approximatelythirty(30)minutes.
2. To ensure accurate temperature readings, add a small amount of water
to TPT9 well. Insert thermometer in TPT9 well.
3. Takereadingseverythirty(30)secondsforfive(5)minutesforatotal
often(10)readings.Theaverageofthesereadingsshouldbe107°F
±2°F.Recordtheaveragevalue.Iftheunitisoutofcalibration,referto
CALIBRATIONsection(p.19).
4. Do not let the pump cool down. Proceed directly to Backup Limit
ThermostatTest.

BACKUP LIMIT 1. With the pump operating properly at 107°F ±2°F, move the primary
THERMOSTAT TEST shortingswitchtotheSHORTposition(seefig.7A/7B,p.22).Thiswill
short out the temperature controller and allow the pump to continue
heatingtothetrippointofthebackuplimitthermostat(s).
2. Carefullyobservetherisingtemperatureandrecordthehighest
reading. When a thermostat opens, the pump will turn off, the OVER
TEMPlightwillbelit,andtheHEATERINDICATORlightonthetest
coverwillturnoff.(IftheOVERTEMPlightdoesnotlightandathermo-
stathastripped,replacethelight.)EithertheMANIFOLDorWELLlight
onthetestcoverwillbelitorbothlightswillbeoff,dependingon
whichthermostatshavetripped.
• Ifthemanifoldthermostatlightison,thenthemanifoldthermostat
has opened. The temperature recorded must be between 110°F to
117°F (43.3°C to 47.2°C). If the thermostat operates outside
its intended range, it must be replaced (see page 18).
Proceedtostep3.
• Ifthewellthermostatlightison,thenthewellthermostathas
opened. The temperature recorded must be between 110°F to 122°F
(43.3°C to 50°C). If the thermostat operates outside its
intended range, it must be replaced (see page 18). Proceed to
step3.
• Ifneitherlightison,thenboththermostatshaveopenedatthesame
temperature.Toconfirmthis,togglethethermostatshortingswitch
to the MANIFOLD position. (The MANIFOLD light should be on.)
Next,toggleswitchtotheWELLposition.(TheWELL lightshouldbe
on.) If either thermostat opens outside its intended range as
defined above, it must be replaced (see page 18). Proceed to
step4.

13
 SERVICE MANUAL
FUNCTIONAL CHECK TP500/TP500C T/PUMP

3. Totesttheremainingthermostat,togglethelimitthermostatshorting
switchtothepositioncorrespondingtothenon-trippedthermostat.
(Thiswillshortoutthepreviouslyopenedthermostatandallowthe
unittocontinueheating.)Boththermostatindicatorlightsshouldbeoff
and the HEATER INDICATOR light should be on. Carefully observe the
risingtemperatureandrecordthehighestreading.Whenthewater
temperaturerisestothetrippointoftheremainingthermostat,the
OVERTEMPlightwillbeon,thepumpwillturnoff,theheaterindicator
lightwillturnoff,andtheappropriatethermostatlightwillbeon.
• Ifthemanifoldthermostatlightison,thenthemanifoldthermostat
has opened. The temperature recorded must be between 110°F to
117°F (43.3°C to 47.2°C). If the thermostat operates outside
its intended range, it must be replaced (see page 18).
• Ifthewellthermostatlightison,thenthewellthermostathas
opened. The temperature recorded must be between 110°F to
122°F (43.3°C to 50°C). If the thermostat operates outside
its intended range, it must be replaced (see page 18).
4. Unplug the unit, remove the test cover and proceed to LEAK TEST.

LEAK TEST 1. Immediately upon completion of Backup Limit Thermostat Test,

reinstallfillcaptightly.Putyourfingerovertheholeinthecapandtilt
unittowardyousothefrontisdown.Holdforthree(3)minutes.
2. Returntheunittouprightpositionandcarefullycheckinsideoftray
andreservoirtrayjointforleaks.Repeatprocessturningpumponback
face.Ifleakageisfound,refertotheDISASSEMBLY/REASSEMBLYsection
(pp.16-18),andcorrectproblem.

COVER AND FILL NECK Whenreinstallingcover,besurethefillneckgasket(fig.11,item6,p.26)

GASKET REINSTALLATION isinplace.Pushcoverdownastightlyaspossible.Holdinplacewhen
tighteningcoverscrews.

This completes the FUNCTIONAL CHECK procedure. Return

pumptoserviceifitisoperatingproperly,orproceedtothe
DISASSEMBLY/REASSEMBLYsectionpertainingtotheproblem(s).

14
SERVICE MANUAL
TP500/TP500C T/PUMP INSPECTION FORM

Inspectionformsvaryfromhospitaltohospital.
Thefollowingsampleformisintendedasaguide
sothattheimportantparametersarerecorded.

T/Pump Functional Check and Safety Inspection Form

Date ______________

Model Number _____________________ Serial Number __________________

Item Value OK? Action Action Taken

Needed?

(check one)

1. Inspect physical condition (line cord, plug, housing)

Inspect electrical compartment

(switches, fuse/circuit breaker)

Inspect hose connections and connectors

2. Lubricate motor

3. Connect TPC1 test cover;

match wire colors of connections

4. Measure ground resistance; <0.5 ohm . . .

indicate value

5. Measure current leakage; <100 µA . . .

indicate value

6. Check tip-over switch

7. Measure flow; > 9 gph (34 lph) . . . indicate value

8. Measure operating temperature @ 107°F ± 2°F . . .

indicate average

9. Record manifold backup limit thermostat trip point;

110°F to 117°F (43.3°C to 47.2°C) . . . indicate value

Record well backup limit thermostat trip point;

110°F to 122°F (43.3°C to 50°C) . . . indicate value

OVER TEMP light operates

10. Check for leakage

11. Reinstall cover and the fill neck gasket

Signature ________________________________________________________________________________

15
 SERVICE MANUAL
DISASSEMBLY/REASSEMBLY TP500/TP500C T/PUMP

DANGER

Risk of electric shock. Disconnect power before servicing the

T/Pump.

WARNING

• OnlyqualifiedmedicalservicepersonnelshouldrepairtheT/Pump.
Improper repair may result in death or serious injury,
equipment damage, or malfunction.
• Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION
(pp.10-14)aftermakingrepairsandbeforereturningtheT/Pumpto
patient use. Document your findings on theINSPECTION FORM
(p. 15). Improper repair may result in death or serious
injury, equipment damage, or malfunction.

CAUTION

Do not perform any powered tests with the reservoir empty.

Damage to the T/Pump may result.

NOTE: Allwiresareterminatedwithslip-onconnectors.
Whentextsays“removewire,”theslip-onconnectoris
toberemovedfromthematinglugonthespecificitem.

COVER 1. Unscrewfillcap/valveassembly(fig.11,item1,p.26)andremove.
Unscrewplasticretainer.
2. Remove the four screws which retain the cover, two on each end of
the pump.
NOTE:Whenreinstallingthecover,donotforgettoreplacethefill
neckgasket(fig.11,item6).

MOTOR 1. Placeascrewdriverunderfanhub(fig.11,item7,p.26)andtwistto
removefan.
NOTE: When replacing the fan, make sure the hub is flush with top of
motorshaft.
2. Remove green ground wire and orange and blue power wires.
NOTE: To prevent breaking the motor lugs, support them when
removingtheslip-onlugs.
3. Remove the four retaining screws and washers on the top face of the
motor.

16
SERVICE MANUAL
TP500/TP500C T/PUMP DISASSEMBLY/REASSEMBLY

4. It is necessary to remove the reservoir to remove the motor. Remove

theeight(8)screwslocatedaroundtheinsidewallofthetray.
NOTE: Itisnotnecessarytoremovethefrontlabel(fig.11,item37,
p.26).Thefrontlabelisattachedonlytothetrayandwillslipoffthe
reservoir.
5. Gently separate the reservoir from the tray. Do not damage the large O
ringthatsealsthetrayandreservoir.
6. Turnthetrayonitsbackside(frontlabelup).Placeascrewdriveragainst
the white impeller in the bottom of the pump housing to prevent the
impellerfromturningandremovethescrewretainingtheimpeller.Itis
notnecessarytoremovethebottomhousing(fig.11,item24,p.26)of
the pump.
7. Theimpellermaynowbeslippedofftheshaft.Returnthetrayassembly
toanuprightposition.Themotormayberemovedbyliftingstraightup.
8. Center the new motor seal gasket over opening and insert new motor
throughseal.Replaceimpellerontoshaftandsecuremotor.
9. Do not overtorque the four (4) motor mounting screws. Torque value is
6to8in.-lbs.
10. If tray inserts are loose or motor mounts are worn, a new tray with
sensorbracketshouldbeinstalled.

HEATER
1. Removethegroundwire(green)andthetwoheaterwires(redandblue).
NOTE: Onreassembly,theredwiregoesonthefrontpostoftheheater.
2. Removethethree(3)nutsretainingtheheater.Thescrewsareretained
inthetray.Theheatercanthenberemovedbyraisingandtiltingthetop
oftheheatertowardtheleftsideoftheT/Pump.
3. Reassemblyisthereverseoftheabove.
4. Donotforgettoinstallheatergasket(fig.11,item11,p.26).

PC BOARD
1. Usingtheplastickey(fig.5,item7,p.9),turnthetemperatureindicator
totheeleveno'clockposition.Theslottedcouplingshouldthenbe
positionedwiththeslotopeningup.
2. Cut the plastic tie holding the wire bundle to the PC board. Remove the
red, orange, and blue wires from the PC board.
3. Remove the two screws (fig. 11, items 56 & 57, p. 26) retaining the PC
board.Theboardcanthenberaisedfromthetray,exposingthether-
mistorprobeassemblyinthebrassmanifoldblock(fig.11,item47,
p.26).Usecautiontobesurenostrainisputonthermistorleads(fine
whitewires).
4. Carefullyremovethethermistorcapsulefromthemanifold.Toavoid
damagingthethermistor,donotpullonthewires.Adentalpickor
scribecanbeusedtoprythecapsuleoutofthehole.

17
 SERVICE MANUAL
DISASSEMBLY/REASSEMBLY TP500/TP500C T/PUMP

5. Onreassembly,putasmallquantityofsiliconeheatsinkcompound
(Dow Corning #340 or equivalent) around the thermistor capsule.
Carefullyinsertthethermistorcapsuleintotheholeonthebrass
manifold block. To avoid damaging the thermistor, do not push on the
wires.Thecapsulemaybeseatedbyplacingneedlenosepliersor
tweezersontheedgeofthecapsule.
6. The remainder of the reassembly is the reverse of the above. Upon
insertingtheP.C.Board,thepotentiometershaft(fig.11,item52,
p.26)mustbeintheverticalpositiontomatewiththeslotinthe
temperatureindicator(fig.11,item40,p.26).RefertoCALIBRATION
procedures(pp.19-20).

MANIFOLD BACKUP 1. Remove the two (2) wire lugs. Note the position of the color coded
LIMIT THERMOSTAT wires.FacingthefrontoftheT/Pump,thepurplewiregoesontheleft
handlug,andtheorangewiregoesontherighthandlug.
2. Remove the two (2) screws retaining the thermostat to the brass
manifoldblock.
3. Reassemblyisthereverseoftheabove.
4. Alwaysbesuretocheckthebackuplimitthermostatsaccordingtothe
FUNCTIONAL CHECK (pp. 13-14).

WELL BACKUP
LIMIT THERMOSTAT NOTE: Do not attempt to replace the well thermostat. To
insureproperoperationofthisthermostat,itisrivetedandsealed
tothetrayassembly.Experiencehasproventhatitcannotbe
successfullyreplaced.Ifthisitemisdefective,replacethe
entire tray assembly (fig. 11, item 17, p. 26).

TRAY 1. Removetheeight(8)screws(fig.11,item15,p.26)aroundtheinside
wallofthetray.Gentlyprythereservoirfromthetray.
2. Removeallcomponentsincludingseal,bushing,andclipsfromtheold
trayandreinstallintothenewtrayassembly.
3. Attachthereservoirtothetray.Checkthatthereservoirringseal
(fig.11,item19,p.26)isproperlylocatedinthegrooveinthetray.
Installtheeight(8)screwstorquedtoapproximately6in.-lbs.
4. Alwaysbesuretocheckthebackuplimitthermostatsaccordingtothe
FUNCTIONAL CHECK (pp. 13-14).

18
SERVICE MANUAL
TP500/TP500C T/PUMP CALIBRATION

DANGER

Risk of electric shock. Disconnect power before servicing the

T/Pump.

WARNING

• Onlyqualifiedmedicalservicepersonnelshouldrepairthe
T/Pump. Improper repair may result in death or serious
injury, equipment damage, or malfunction.
• Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION
(pp.10-14)aftermakingrepairsandbeforereturningtheT/Pumpto
patient use. Document your findings on theINSPECTION FORM
(p. 15). Improper repair may result in death or serious
injury, equipment damage, or malfunction.

CAUTION

Do not perform any powered tests with the reservoir empty.

Damage to the T/Pump may result.

CALIBRATION TPT9 ---------- GAYMAR Flow and Temperature Tester

EQUIPMENT [When testing TP500C, use also an
Adaptor Hose Assembly, P/N 77926-000)
TPC1 --------- GAYMAR T/Pump Test Cover
TFC1 ---------- Thermometer, 30°F to 125°F (-2°C to 52°C), 1°C
accuracy,12"long,3"immersion(e.g.,Brooklyn
Thermometer #73544 or equivalent)
Insulatedalignmenttool
T/Pad --------- Any GAYMAR “12” or “22” series T/Pad;
or, TP612 or TP622 pad as applicable

Thecalibrationshouldbeperformedinatemperaturecontrolledroom,
between 70°F and 75°F.

CALIBRATION 1. Remove the pump cover by removing the two (2) screws at each end
ofthepump.Thefillcap/valveassemblycanberemovedbyunscrewing
thecapandplasticretainer.Thecoverisnowfreetoberemoved.

2. CarefullyremovethebluetorquesealfromtheR3trimpot(fig.12,
item 63,p.27),locatedatthetoprightcorneroftheprintedcircuit
board.

3. Installtestcover.SeeFUNCTIONALCHECK(p.12)andfigures7A/7B.

19
 SERVICE MANUAL
CALIBRATION TP500/TP500C T/PUMP

4. Connect pump, pad, TPT9 flow/temp tester, and adaptor hose assem-
blyifrequired(seefig.8,p.23).

5. Fillpumpwithroomtemperaturedistilledwater.

6. Set Temp Dial to 107°F (maximum).

NOTE: Besurethetemperaturedialisalwayssettothe
maximum clockwise position when making
calibrationmeasurementsandadjustments.

7. Theprimaryshortingswitch(fig.7A/7B,p.22)onthetestcovermust
beintheOPENposition.Thebackuplimitthermostatshortingswitch
(fig.7A/7B)mustbeintheOPENposition.

8. Turn unit on and allow to come to a steady temperature, approxi-

matelythirty(30)minutes.
The HEATER INDICATOR on the cover should be on whenever the
heaterison.

NOTE: Flow must be 9 gph, minimum.

If not, refer to TROUBLESHOOTING(p. 21).

9. Startrecordingthetemperaturereadingseverythirty(30)secondsfor
five(5)minutesforatotaloften(10)readings.Theaverageofthese
readingsshouldbe107°F±2°F.Ifnot,itwillbenecessarytoadjustthe
R3trimpot(fig.7A/7B,p.22).Thisisaccomplishedbyinsertingan
insulatedalignmenttoolthroughthesmallholeintheleftsideofthe
TPC1 test cover. Turn the potentiometer screw clockwise to increase
the water temperature. Turn the screw counterclockwise to decrease
thewatertemperature.
Do not force the adjusting screw past its stops.

10. Afterthefinaladjustmentismade,lettheunitrunforone-halfhour
andrecheckthecalibrationasdescribedinstep9.Thebandwidth
shouldnotexceed2°F.Bandwidthisthedifferencebetweenthe
maximum and minimum temperature excursions. If the OVER TEMP
lightisactivatedduringthecalibrationadjustment,thewatermustbe
replacedwithwater75°Forlessandthecalibrationprocedure
repeated.

11. Withoutlettingthepumpcool,proceeddirectlytotheBackupLimit
Thermostat Test as outlined in the FUNCTIONAL CHECK (p. 13).
Recordallresultswhenrecalibrating.
Applybluetorquesealafterthetrimpothasbeenadjustedproperly.

20
SERVICE MANUAL
TP500/TP500C T/PUMP TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE REMEDY

"OVER TEMP" light is 1. Pad or hose is kinked. Hose clamps are closed. Turn switch off, unplug pump, and dump water out. Unkink pad and/or
on. hose. Open hose clamps. Refill with room temperature distilled water
to proper level.
2. Water level is low, or reservoir is empty. Plug pump in, turn switch on, and wait 40 minutes.

3. Pump is filled with water that is too hot

(it must be below 75°F).

4. One of the backup limit thermostats has failed. Unplug pump and install a test cover. Determine which thermostat has
failed. Refer to Backup Limit Thermostat Tests (p. 13). Replace
thermostat (p. 18).

5. PC board (temperature controller) has failed. Unplug pump, install test cover, and perform Calibration (pp. 19-20).
Replace PC board as required (pp. 17-18).

T/Pump will not pump. 1. Water level is low, or reservoir is empty. Refill with room temperature distilled water to proper level.
ON/OFF switch pilot
light is lit.
2. "OVER TEMP" light is on. Refer to "OVER TEMP" section above.

T/Pump will not pump. 1.
ON/OFF switch pilot
light does not light.
2.
The "ON" switch may not be fully engaged. The light on the switch should be lit. Verify that the switch is fully
engaged in the "ON" position.
The electrical cord is not plugged into a Insert the plug fully into the receptacle.
grounded electrical receptacle.

3. Check circuit breaker. If center button has Unplug T/Pump. Determine cause. Reset breaker.
moved forward exposing white band, breaker
has tripped.

4. Damaged cord or plug, or break in continuity Check plug terminals. Check power cord continuity to breaker.
between cord and breaker. NOTE: Flex cord while checking continuity. Replace power cord
assembly as required.

T/Pump pumps OK, but 1. Unit is tipped. Place unit on level surface.
will not heat.
2. Heater is not receiving power, or is defective. Check if setpoint has been set too low. Remove cover and check
power to heater. If power is present, heater is probably defective. Cold
heater resistance is approximately 80 ohms. Replace if required. If
there is no power at heater terminals, replace PC board.

3. "OVER TEMP" light is on. Refer to "OVER TEMP" section above.

T/Pump pumps OK, but 1. ON/OFF switch defective. Replace ON/OFF switch. NOTE: Neon pilot light is not replaceable.
ON/OFF switch pilot
light does not light.

Flow rate is less than 1. Flow path is restricted or obstructed. Be sure pump is at same level as pad, pad is flat, and water
9 gph. temperature is 107°F. (Flow is specified under these conditions.) Look
for obstructions in the flow path. Open hose clamps. The orifice in the
return hose fitting (fig. 5, item 10, p. 9) is the smallest hole.

2. Motor is malfunctioning. See #1 above. If flow path is clear, replace motor.

Current leakage is too 1. Heater will be the most probable cause. Disconnect heater and check again. Replace heater if necessary. If
high. current leakage remains high, continue disconnecting components until
fault is located.

Resistance to ground 1. Cord or plug connection(s) will be most probable Check that connections are tight (applies to older style [non-molded
failure (greater than cause. type] plugs). Disconnect power lead at circuit breaker and switch.
0.5 ohm) Measure resistance of power cord alone. Replace if necessary. If
problem persists, check grounding wire to each component for
continuity.

Water leaks from Connector:

Clik-Tite Connector 1. Damaged O ring. If defective, replace Clik-Tite connector.

2. Locking ring on Clik-Tite connector is not Snap Clik-Tite locking ring shut.
snapped into place (see fig. 3, p. 5).

Colder-style 3. The couplings are not securely connected. Push the male and female ends together until you hear a "click." If it still
Connector leaks, replace connector.

21
 SERVICE MANUAL
TPC1 TEST COVERS TP500/TP500C T/PUMP

Figure 7A—‘NEW’ STYLE TPC1 TEST COVER

CAUTION
NOTE:
Route TPC1 wires as shown to avoid Always match color of TPC1 wiring
interferencewithT/Pumpfanmotor. connectionstocolorof T/Pumpwiring.

22
SERVICE MANUAL
TP500/TP500C T/PUMP TEST SETUP

Figure 8A—FUNCTIONAL CHECK TEST DIAGRAM (TP500)

Figure 8B—FUNCTIONAL CHECK TEST DIAGRAM (TP500C)

23
 POWER SWITCH

24
WHITE BLUE J1
NEUTRAL
GRN R4 D1
120V
3.9K 5% 1N4007 R10
BLACK YELLOW VIOLET ORANGE 200
LINE
3A GRN GRN R3 150W,
CB1

HEATER
20K 1% 80 OHM COLD
CIRCUIT BREAKER S2 S3 R5
B1
THERMOSTAT THERMOSTAT SETPOINT
PUMP
WELL MANIFOLD 7 1 5
GRN R2 R1 J3
SNAP-ACTION SNAP-ACTION 2 -
931 1% 15K 5% Q1
DISC DISC
3 + 6 2N3904

+
D2 4 U1
LM741 D3 S1
1N5236B C1
100uF 25V 1N914 SWITCH,
TILT MERCURY
D4
DS1 RT1 1N914
OVERTEMP 1 6
LIGHT R8
18.7K 1% 2 5
3 4
Q2
U2
D5 BTB12
MOC3063
R9 1N4007 R6
510 390
R7
J2 390
Figure 9—CIRCUIT DIAGRAM
CIRCUIT DIAGRAM, T/PUMP

Switchwiring:

NOTES: Larger
1. ALL RESISTANCES ARE IN OHMS. switch
2. ALL RESISTORS ARE 5% CARBON UNLESS NOTED.
3. ALL CAPACITORS ARE IN MICROFARADS UNLESS NOTED.
4. REFERENCE: THIS DRAWING CORRELATES TO GAYMAR DRAWING
(B) 11958-000 REVISION NONE.
5. CAUTION: THE ACTUAL ASSEMBLIES ARE SUSCEPTIBLE TO DAMAGE FROM
ELECTROSTATIC DISCHARGE. HANDELING OF THIS PRODUCT SHALL BE
FRONT VIEW REAR VIEW
ACCOMPLISHED ONLY WITH A DEQUATE PROVISION TO PREVENT
ATTENTION ELECTROSTATIC DISCHARGE DAMAGE.
Static-Sensitive
Devices

Smaller
switch

FRONT VIEW REAR VIEW

TP500/TP500C T/PUMP
SERVICE MANUAL
SERVICE MANUAL
TP500/TP500C T/PUMP CIRCUIT DIAGRAMS, TEST COVERS

Figure 10A—CIRCUIT DIAGRAM FOR TPC1 TEST COVER

(To connect, refer to figure 7A)

25
 SERVICE MANUAL
EXPLODED VIEW TP500/TP500C T/PUMP

Figure 11—EXPLODED VIEW

26
SERVICE MANUAL
TP500/TP500C T/PUMP REPLACEMENT PARTS

Item P/N Qty Description

1 04553-001 1 Cap/Valve Assembly
2 77875-000 1 Handle (Replacement Kit) [Included with item 4]
3 08632-000 1 Instruction Label [Included with item 4]
4 08087-000 1 Cover Assembly [includes items 2, 3, 58, and 59]
5 90085-033 4 Fastener Clip [Included with item 4]
6 03650-000 1 Fill Gasket
7 04152-000 1 Fan
8 77121-000 1 Motor Kit [includes item 13]
9 91190-002 3 Nut, 6-32 SST
10 04013-000 1 Heater (120V)
11 05069-000 2 Heater Gasket
12 90085-003 1 OVER TEMP Light Clip
13 04877-000 1 Motor Seal Gasket [included with item 8]
14 90085-041 1 Circuit Breaker Clip
15 91272-011 8 Screw, 6-20 x 5/8", type B, SST
09019-000 1 UL Label, TP500 [included with item 17]
16
10408-000 1 UL Label, TP500C [included with item 17]
78009-000 1 Tray w/ Sensor Brkt, Thrmostat* TP500 [includes items 16, 18, 37]
17
78009-001 1 Tray w/ Sensor Brkt, Thrmostat* TP500C [includes items 16, 18, 37]
18 08242-000 1 Warning/Caution Label [included with item 17]
19 07968-000 1 Reser voir Seal
20 90018-061 4 Screw, 6-32 x 1/2", SST
21 03567-000 1 Pump Housing
22 03611-000 1 Impeller
23A 90018-057 2 Screw, pan head, 6-32 x 1/4", SST
23B 91454-052 2 Screw, fillister head, 6-32 x 1/4", SST

* Thewellbackuplimitthermostatispartofthetrayassembly.
Do not attempt to drill out the old thermostat. A leakproof installation is not possible.
Installtrayassembly(seep.18).

27
 SERVICE MANUAL
REPLACEMENT PARTS TP500/TP500C T/PUMP

Item P/N Qty Description

24 03568-000 1 Bottom Housing
25 90514-011 6 Screw, 6-20 x 5/8", type BT, SST
Serial Number Label [included with item 28;
26 1
NOT AVAILABLE SEPARATELY]
27 08090-000 1 Hospital Identification Label [included with item 28]
28 77867-000 1 Reser voir (Replacement Kit) [includes items 26, 27, 29]
29 04257-001 1 Water Level Label [included with item 28]
30 90385-000 4 Suction Cup
31 81002-000 1 Tubing, 1/4" ID x 3-1/2" long
32 90500-000 1 Circuit Breaker w/ Clip
33 03394-000 2 Manifold Fitting
34 03881-000 1 Brass Bearing Washer
35 78301-000 1 Switch Kit (120V)
36 91282-007 1 OVER TEMP Lamp with clip
37 11184-000 1 Front Label [included with item 17]
38A 08086-000 1 Hose Assembly, TP500 [includes items 41A and 41B]
38B 08648-000 1 Hose Assembly TP500C [includes item 42]
39 91275-027 2 Screw, 4-40 x 3/8", SST
40 03975-000 1 Indicator
41A 03887-000 1 Male Clik-Tite [included with item 38A]
41B 03884-000 1 Female Clik-Tite [included with item 38A]
Female Colder-style Connector, TP500C
42 78028-000 2
[included with item 38B]
43 90076-018 1 Strain Relief Bushing
44 78315-000 1 Power Cord Kit with molded plug
45 03989-000 1 Hose Fitting (orificed)
46 03988-000 1 Hose Fitting (no orifice)
47 03983-000 1 Brass Manifold Block
48 03381-000 1 Manifold Gasket
49 90255-000 1 Plug (replacement)

28
SERVICE MANUAL
TP500/TP500C T/PUMP REPLACEMENT PARTS

Item P/N Qty Description

50 90436-000 1 Fibre Washer
51 90085-015 1 Fastener Clip
52 03969-000 1 Potentiometer Shaft
53 78053-000 1 Backup Limit Thermostat (manifold)
54 90462-000 2 Spacer
55 77869-000 1 PC Board Assembly, includes thermistor
56 90139-004 2 Lockwasher, Internal
57 90018-025 2 Screw, 4-40 x 1/4", SST
58 07999-000 1 LOGO Label [Included with item 4]
59 Hose Strap [Included with item 4. NOT AVAILABLE SEPARATELY]
60 03661-000 2 Temperature Adjusting Key [NOT SHOWN]
61 TFC1 1 Thermometer [NOT SHOWN]
62 TPC1 1 Test Cover [NOT SHOWN]
63 TPT9 1 Flow and Temperature Test Tool [NOT SHOWN]
64 77926-000 1 Hose Adaptor Assembly [see figure 8B]

29
 SERVICE MANUAL
WARRANTIES TP500/TP500C T/PUMP

WARRANTIES GAYMAR equipment and products are warranted against defects in

material and workmanship under normal use and operation from the date
ofpurchaseforthetimeperiodslistedbelowfortherespectiveequipment
and products. Except for such warranty, GAYMAR disclaims all
other express and/or implied warranties including, but not
limited to, the implied warranties of merchantability and of
fitness for a particular purpose.

PUMP Alllaborperformedandpartsprovidedfreeofchargeforaperiodofone
(1)fullyearfromthedateofpurchase,providedtheequipmentisreturned
withpriorauthorization*prepaidtoanauthorizedGAYMARservice
centerorthefactory.

PAD, SINGLE Freereplacementofproductwheredefectsinmaterialsand/or

PATIENT USE workmanshipareevidentattimeofdeliveryprovidedtheproductis
returnedwithpriorauthorization*prepaidtoGAYMARIndustries.

PAD, REUSABLE Freereplacementofproductwheredefectsinmaterialsand/or

workmanship occur within 90 days from date of delivery provided the
product is returned with prior authorization* prepaid to GAYMAR
Industries.

PARTS Defectivepartswillbeexchangedfreeofchargewheredefectsinmaterials
and/orworkmanshipoccurwithin90daysfromdateofdeliveryprovided
the parts are returned with prior authorization* prepaid to GAYMAR
Industries.

* Forpriorauthorizationonallitemsbeingreturnedtothefactoryand
for a Return Goods Number (RG#), call Customer Service at
(716)662-2551
1 800 828-7341

30
SERVICE MANUAL
TP500/TP500C T/PUMP

31
 SERVICE MANUAL
TP500/TP500C T/PUMP

32
SERVICE MANUAL
TP500/TP500C T/PUMP
 ®

GAYMAR INDUSTRIES, INC.

10 Centre Drive
Orchard Park, NY
14127-2295

Phone:
1 800 828-7341
(716) 662-2551

FAX:
T/PUMPS® AND T/PADS® 1 800 993-7890
ARE MADE IN THE USA (716) 662-0748